Normal Operations

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Normal Operations
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What are we going to do today?

• Upload proper formula
• Start skid process
• Adjust Brine and Citric addition rate as needed
• Adjust heat exchanger temperature set point (line
  13 only)
• Demonstrate how to operate Beckman and Brookfield
  instruments
• Calibrate Beckman pH meter
• Identify pH range for an acid and a base
• Explain the need for adding citric acid to some
  formulas
• Tote and Drum Change
• Lock out loops
• Change totes and / or drums prior to surge tank
  low level
• Restart loops

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The Basics

• How to upload a formula can be found in all of
  our changeover SOPs.
• How to start the skid process and what to look
  for is in every changeover SOP, and some was
  covered in your first few Operation Technician
  Three training.
• Making Citric Acid and Brine adjustments can be
  complicated when not understanding when to do it
  or why we need to do it.
• Question you need to ask yourself
• What is my specification range for viscosity and
  or pH.
• How do you trend your adjustments
• What test can you do to confirm you have made the
  correct decision

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Heat Exchanger for Line 13
Line 13 Heat Exchanger. Manual controls in
electric room 5
Heat exchanger temperature controls can be seen
on the bottom of the formula screen. When heat
exchanger is active. Heat exchanger will turn
RED!
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K-TRON BEAD FEEDER
These are the screws we use on line 13
Our materials are held in a hopper and constantly
feed into refill hopper. As the feeder discharges
material, system weight declines. The
loss-in-weight feeder controller adjusts feeder
speed to produce a rate of weight loss or process
variable equal to the desired feed rate setpoint.
When adding materials to the system while
processing, we are adding weight to the system in
error. We required the system to make adjustments
of speed based on erroneous information. That is
why we require operators to not add materials
while the line is processing. Simple vibrations
and putting objects on the systems load cells
will also require the system to make adjustments
based on erroneous information.
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Beckman pH meter
A simple and speedy device to measure the acidity
and alkalinity of a fluid. A pH meter acts as a
volt meter that measures the electrical potential
difference between a pH electrode and a reference
electrode and displays the result in terms of the
pH value of the solution in which they are
immersed. The pH meter was invented in 1934 by
the American chemist Arnold O. Beckman
(1900-2004) to measure the sourness of lemons.
Beckman's original device was housed in a walnut
box 12 inches wide, 8 inches deep and 9 inches
high. It measured electrical current flowing into
a glass electrode immersed in a solution. The
amount of current indicated the solution's
acidity.
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Brookfield
The ability to gather data on a material's
viscosity behavior gives manufacturers an
important "product dimension". Knowledge of a
material's rheological characteristics is
valuable in predicting pumpability and
pourability, performance in a dipping or coating
operation, or the ease with which it may be
handled, processed, or used. The interrelation
between rheology and other product dimensions
often makes the measurement of viscosity the most
sensitive or convenient way of detecting changes
in color, density, stability, solids content, and
molecular weight.
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Temperature!

• Temperature one of the most obvious factors that
  can have an effect on the rheological behavior of
  a material. Some materials are quite sensitive to
  temperature, and a relatively small variation
  will result in a significant change in viscosity.
  Others are relatively insensitive.
• Testing our products at 25 degrees Celsius and
  the change in viscosity at a degree higher or
  lower helps us understand the need for accuracy
  and just how temperamental our products can be!

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Effect of Temperature
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Changing totes and restarting skid to process

• Disconnect post add containers for the prior
  formula and hook up the containers for the new
  formula using clean hoses. Place the previously
  used hoses on the hose-cleaning cart.
• Place the out-feed for the recirculation loop in
  a clean container for purging.
• Manually adjust the control valves (if applied)
  to 85.
• Manually open in-feed valve.
• Start the pumps at 50 capacity and purge both
  for approximately 15 seconds. Monitor the
  color/appearance of the effluent to ensure
  effectiveness and purge longer if needed.
• Close post-add pump in-feed valves when the purge
  process is complete.
• Remove the out-feed for the recycle loops from
  the clean containers used for purging and place
  in the proper feed containers.

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Questions?
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Feedback

• Ongoing improvement requires feedback Give
  some!

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Your Assessment Responsibilities

• You will need to demonstrate the ability to
  upload proper formula with a clear understanding
  on the how to start skid process.
• Demonstrate the ability to make brine and citric
  acid adjustment and give examples of how and why
  we do this.
• Give examples and state products that require the
  use of the heat exchanger and demonstrate the
  path of flow through the heat exchanger.
• Obtain instructions from your trainer and proceed
  to calibrate the Beckman pH meter.
• Obtain a sample from any production line and
  proceed to do a Beckman pH meter test and do a
  Brookfield viscosity test.
• Describe the reasoning behind the desire
  temperature value of 25 degrees Celsius
• Adjust heat exchanger temperature set point (line
  13 only). If the product is too hot or cold what
  does that do to our viscosity and fill weights?
• Why can we not add beads to the K-TRON feeder why
  line is processing?
• Tote and Drum Change, what are the procedures for
  changing a tote or drum?